Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

• Published in: Proceedings of the Institution of Mechanical Engineers. Part B, Journal of engineering manufacture Journal of engineering manufacture, 2020-02, Vol.234 (3), p.610-620
• Main Authors: Pham, Thi-Hoa, Nguyen, Duc-Toan, Banh, Tien-Long, Tong, Van-Canh
• Format: Article
• Language: English
• Subjects: Aluminum alloys; Aluminum base alloys; Chip formation; Contact length; Cutting parameters; Cutting speed; Face milling; Feed rate; High speed machining; Milling industry; Morphology; Plastic deformation; Surface roughness; Vibration measurement; Workpieces
• ISSN: 0954-4054; 2041-2975
• DOI: 10.1177/0954405419863221

In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured under varying cutting conditions (cutting speed, feed rate, and depth of cut). The characteristics of chip morphology were observed using scanning electron microscope. Experimental results showed that the increasing cutting speed reduced the tool–chip contact length, the workpiece vibration, and the surface roughness. The tool–chip contact length, the workpiece vibration, and the surface roughness were all increased with increasing cutting depth and feed rate. The results of chip morphology showed that the chips with serrated form were generated under high-speed cutting conditions. Moreover, scratch lines, plastic deformation cavities, and local molten chip material were observed on the slide chip surface.